| China is a large garment producing country,and the rising labor cost has caused unprecedented impact and challenge to the textile and garment industry.As cheap labor can no longer be a competitive advantage,how to change the traditional crude production method and reduce the pressure of rising costs has become a problem that many garment enterprises need to face.In this market environment,the textile and garment industry urgently needs to optimize the production process through data empowerment,transform to digitalization and intelligence,and enhance its core competitiveness.Company L,a garment manufacturing company,is facing the problems of rising labor costs and shortening order cycles in its current production operations.Considering the current development situation,this paper takes the shirt production process of Company L as the research object to design and implement an optimization plan.Firstly,we collect data related to the production process through field research,draw the shirt production process procedure table,and find out the problems in the shirt production process.Secondly,we designed and implemented an overall optimization plan: for the process flow,according to the "5W1H" questioning method and the "ECRS" principle,we used two-hand operation analysis and human-machine operation analysis to merge and simplify the key processes.We use genetic algorithm to balance the production line,rearrange the optimized processes,improve the intensity of production load between work stations,and shorten the production cycle.In terms of shop layout,we use the system layout method to design various shirt production shop layout solutions,and evaluate alternative solutions based on gray correlation analysis.Using Flexsim simulation software,we simulated and implemented the layout solution with the highest evaluation score and compared it with the original one to verify the effectiveness of the optimized solution.In terms of site management,we carried out 6S site management activities to improve the environmental hygiene of the production site and enhance the work quality of the operators.Implemented visualization management program to clearly present the information of shirt production process.RFID identification devices were installed in different production areas to collect and detect data in the shirt production process to improve production data processing efficiency.Finally,the shirt production process optimization effect is evaluated by comparing key indicators such as production balance rate and production smoothing index,and corresponding guarantee measures are proposed for the optimization implementation scheme.Through the research of this paper,it can not only solve the problems of the current shirt production process of L Company,improve the shirt production efficiency and enhance the core competitiveness of the enterprise,but also provide references for the production process optimization research of similar manufacturing enterprises. |
